12
Examine the torch..........................................................................................................................256
Examine the torch receptacle..................................................................................................... 258
Examine the torch lead............................................................................................................................ 259
Indicators of emitter wear...................................................................................................................................259
Measure the pit depth of an electrode............................................................................................................ 261
Coolant maintenance...........................................................................................................................................262
Calculations for total coolant volume estimates................................................................................ 263
Total estimated volume in liters.................................................................................................. 263
Total estimated volume in U.S. gallons.....................................................................................263
Coolant replacement and its significance...........................................................................................263
Remove old coolant from the system........................................................................................264
8 Diagnostics and Troubleshooting...............................................269
Safety considerations..........................................................................................................................................269
Initial inspection steps.........................................................................................................................................273
Remove the power from the cutting system.......................................................................................274
Examine each PCB...................................................................................................................................274
Measure the line voltage between the terminals inside the plasma power supply....................276
PCB names and locations......................................................................................................................277
Diagnostic code conventions............................................................................................................................ 277
Diagnostic codes..................................................................................................................................................278
General troubleshooting procedures...............................................................................................................293
Causes of decreased consumable life.................................................................................................293
Cuts are started or stopped off the surface of the workpiece............................................293
The cut settings are not correct.................................................................................................294
The cutting material is magnetic................................................................................................ 294
Cutting faults that can occur frequently.............................................................................................. 294
The pilot arc starts but does not transfer to the workpiece.................................................294
The plasma arc does not cut completely through the workpiece, and there is too much
sparking on top of the workpiece.............................................................................................. 294
There is dross on the bottom of the cut...................................................................................295
The angle of the cut is not square............................................................................................. 295
Do a gas leak test..................................................................................................................................... 295
Coolant flow measurements...................................................................................................................298
Use the CNC or XPR web interface to measure coolant flow........................................... 298
Do a container test to measure coolant flow.......................................................................... 299
Do a test for continuity between the nozzle and workpiece........................................................... 301
Safety consideration for the XPR460...................................................................................... 301
Contents
811530 Instruction Manual XPR460
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